The Design of Ultrasonic Metal Welding with Dual Axes and Its Processing Parameters

• Main Authors: Jyun-Chi Jhan, 詹峻棋
• Other Authors: Kuen-Ming Shu
• Format: Others
• Language: zh-TW
• Published: 2013
• Online Access: http://ndltd.ncl.edu.tw/handle/kzenet

碩士 === 國立虎尾科技大學 === 機械與電腦輔助工程系碩士班 === 101 === This study primarily analyzes and investigates two-axis ultrasonic metal welding processing. Typically, ultrasonic metal welding employs a single axis, which involves uniaxial movement, friction, and welding. This study adopts two axes, which allows two ultrasonic horns to oscillate horizontally and vertically, enabling vibrational friction in the vertical direction in addition to the original horizontal direction, thereby achieving better welding results. Ultrasonic horns are critical in ultrasonic metal welding, because the quality of these horns influences the effectiveness of ultrasonic welding processing. Therefore, a usable ultrasonic horn must be designed. In this study, we designed a two-axis ultrasonic horn, which works both horizontally and vertically. During the design process, ANSYS finite element analysis software was used to simulate the analysis of ultrasonic horn model. Regarding the design dimensions, Taguchi’s nominal-the-best characteristic was applied to determine target values corresponding to the design and identify an ultrasonic horn applicable for the frequency of the ultrasonic generator. Subsequently, the frequencies of the optimized ultrasonic horns were measured using a frequency measurement instrument, followed by simulations and comparisons. The results show that the simulation values approximate the measured values and both values correspond to the frequency of the ultrasonic generator. In addition, considerable amount of time required for the testing and modification of ultrasonic processing can be reduced. The two ultrasonic horns were employed in a subsequent ultrasonic metal welding experiment. After completing the experiment, a component analysis was performed to observe the contact area by using an electron probe micro analyzer (EMPA). A tensile testing machine and the Taguchi method were used to calculate optimal parameters for manufacturing processes. Furthermore, the most influential factors and contribution rates were achieved using the analysis of variance to improve the quality of processing.